Wort production

ABSTRACT

A METHOD OF PRODUCING WORT BY THE ACTION ON A MASH OF STARCH LIQUEFYING ENZYMES, SACCHARIFYING ENZYMES AND PROTEOLYTIC ENZYMES INCLUDES SUBJECTION OF THE MASH TO HYDRODYNAMIC CONDITIONS SUCH THAT A THIXOTROPIC REDUCTION OF VISCOSITY IS OBTAINED TO FACILITATE THE ACTION OF THE STARCH LIQUEFYING ENZYMES.

July 25, 1972 D. H. CLAYTON ET AL 3,679,431

WOR'I' PRODUCTION Filed May 13, 1969 HENRY H.CLAYTON and. JOHN KARKALA? INVENTO 5 a ti bama;

United States Patent "ice Int. Cl. ClZc 7/00 p US. Cl. 9952 g 14 Claims ABSTRACT OF THE DISCLOSURE A method of producing wort by the action on a mash of starch liquefying enzymes, saccharifying enzymes and proteolytic enzymes includes subjection of the mash to hydrodynamic conditions such that a thixotropic reduction of viscosity is obtained to facilitate the action of the starch liquefying enzymes.

PRIOR APPLICATION Great Britain May 15, 1968, application No. 23,028/68. Great Britain Apr. 22, 1969, application No. 20,409/ 69. This invention is concerned with improvements in or relating to wort production.

- Wort contains in addition to fermentable carbohydrates, soluble nitrogeneous compounds. Barley malt is the traditional raw material for the production of wort since it provides a source of carbohydrates and "nitrogen com pounds and in addition provides the enzymes capable of degrading the carbohydrates and nitrogen compounds to the soluble components of wort.

Malt is manufactured from e.g. barley by the process of malting. This consists of first germinating and then drying barley grain under controlled conditions.

1 The manufacture of malt is expensive because 1) large capital investments are necessary for the malting machinery, (2) a skilled labour force is required to operate the malting machines, (3) malt can only be made successfully from the higher qualities of barley which are expensive and (4) during the malting process a physical loss in dry matter occurs; this is known as the malting loss.

It is an object of the invention to provide an improved method of producing a wort in which the use of barley malt is reduced or virtually eliminated. I

We have found that wort may be produced by treating an aqueous slurry of starchand protein-containing plant material for example unmalted cereal grain e.g. finely 3,679,431 Patented July 25, 19 .72

It appears that said hydrodynamic conditions result in the formation of a homogeneous mass very suitable for the action of the starch liqefying enzyme.

, Examples of starchand protein-containing plant materials other than ce'rals include roots, fungi material and by-products of processes to which 'cereals have been subjected.

Examples of suitable materials include tapioca and rice, as well as wheat, barley and maize.

In cases where nitrogen content of the material is low it may be necessary to add minor amounts of soluble protein to the wort in order to make a wort suitable for the production of beer. v j

A commercial enzyme preparation comprises an enzyme which has been extracted and purified industrially. It may be used for example supported on a solid substrate or in the form of a solution.

The invention provides a method of producing wort from an aqueous slurry of starchand protein-containing plant material comprising the steps of liquefying starch by treating the slurry with a commercial starch liquefying enzyme subjecting the slurry to hydrodynamic conditions such that a substantial thixotropic reduction of viscosity is produced by shearing forces in the slurry to facilitate the action of the starch liquefying enzyme prior to any substantial reduction of viscosity resulting from the enzymatic liquefication converting starch to sugar by treatment with a saccharifying enzyme and converting protein to soluble nitrogen-containing compounds by treatment with a proteolytic enzyme.

' The invention also provides wort when produced by a method as set out in the last preceding paragraph.

The invention also provides a process forbrewing beer including such a method.

The invention also provides beer when produced by such a process. 1

The invention also provides a process of producing a concentrated wort syrup by concentrating wort produced by such a method.

The invention also provides a concentrated wort syrup when produced by such a process.

Preferably the cereal grain is ground to a particle size to all pass through a 20-40 British Standard Mesh and its concentration-in the slurry is between 10 and 30 grams per cc. more preferably 25 grams per 100cc. Preferably the hardness of the water of the slurry is between feet at about 86 C.; the bacterial a-amylase may, for example, be derived from the following well known sources:

Bacillus subtilis Bacillus cereus Bacillus polymyxa Bacillus megaterium Bacillus amyloliquefaciens a cooling Preferably the slurry is treated with the starch liquefyby weight total solids, morepre'frably about 80%.

ing enzyme at a temperature between 60 Cfahd 100 C.'

for example between 80 C. and 90 C., more preferably about 86 C.; preferably the pH is between 6 and 8, more preferably about 6.5. By treating the slurried material with a liquefaction enzyme at the specified temperature a product may be formed which does not gelatinize on cooling. When heating the slurried mixture, gelatiniza- Bacillus mbtilis Bacillus cereus Bacillus polymyxa Bacillus inegaterium Bacillus amyloliquefaciens fungal protease may, for example be derived from the following well known sources:

Rhizopus sp Aspergillus' flavus oryzae Aspergillus oryzae Aspergillus tamarii Aspergillus niger The saccharifying enzyme is for example p-amylase added in the form of ground malt. Commercial p-amylase may for example be derived from soya. The malt preferably has a diastatic activity between 40 and 100 Lintner. For'example between 2% and 10% malt by weight of cereal grain (as is) is used. Other saccharifyingenzymes maybe used e.g. amylglucosidase or fungal amylase.

' Preferably the medium is treated with the proteolytic enzyme and the saccharifying enzyme simultaneously at a temperature between 25 C. and 60 C., more preferably about 55 C. the medium being cooled to the required temperature following the liquefaction step; preferably the pHis between 4.5 and 6.5, more preferably 5.5. Proteolytic enzymes show optimum effect at a temperature. of between 25 C. and-60 C. and at a pH-value of between 4. and 10. Saccharifying enzymes also have optimum effect at 25- 60 C. and at a pH-value of 4.6. Thus, by cooling the liquefied product to a temperature within said temperature range and adjusting the pH-value to between and 6 preferably 5.5 an optimum effect of both the proteolytic enzy-mes andthe saccharifying enzymes is obtained.

Following the treatment with proteolytic enzyme and *saccharifying enzyme the resultant wort is, for example,

' filtered and'ipassed directly to normal subsequent processing to produce beer. Alternatively, for example, the wort filtered and evaporated to a syrup which is-stored and Ysubsequently diluted to provide a wort for normal subse- Preferably the syrup contains between 75% and 82% There now follows a description to be read with reference to the accompanying drawings, of apparatus for carrying out a method embodying the invention. This description is given by way of example of the invention only and not by way of limitation thereof.

In the accompanying drawings:

FIG. 1 shows a flow diagram of the apparatus; and

FIG. 2 shows a cross-section through a heat exchanger forming part of the apparatus.

In the drawings, 1 indicates a vessel in which commercial bacterial a-amylase is mixed with a slurry of finely ground unmalted barley; the barley may be wet ground or ground in a dry condition. From the bottom of the vessel 1, a pipe 2 leads to an inlet 4 of a diaphragm pump 3 of the type in which the diaphragm is hydraulically operated by means, of a reciprocating piston. Anoutlet 5 of the diaphragm pump 4 is connected through a pipe 6 with a heat exchanger 7, and to an outlet endof the heat exchanger I there is 'connectedconduit means comprising a; tubular reactor 8. A valve 2 is providedin a-pipe'counecting the tubular reactor 8 with a cyclone collector.10. Thebottom of said cyclone collector 10 is connected, through apip'e 11 in which a pump 12 is provided, to a series of continuous reactor vessels 13. The last reactor vessel in said series is connected with an inlet end of a cooler 14. A 'pipe 15 is connected to an outlet end of said cooler '14 and by means of a valve (not shown) material passing through thepipe 15 can be passed alternately to one of two saccharification tanks 16 which are provided with mixers and with jackets 17 for circulation of a liquid to maintain a constant temperature. The pipe 15 has a branch pipe 18 which iscon} nected with an acid reservoir 19 through a pump 20.

Pipes 21 are provided to introduce malt or other saccharifying enzymes and proteinase into the saccharifaction tank 16. 7

A pipe 22 in which a pump 23 is provided connects thesaccharification tanks 16 with a heater '24. Anon other. An annular passage 36 for' the medium "to be thetubularreactor 8 ;que t processing; the wort is preferably filtered without If it is used as a source of the saccharifying enzyme orif starchis as an enzyme substrate it is preferred 'to heat the medium treated with proteolytic and sacchari- 80 C.'e. g. about 75 C. before further processing. In this manner the non-gelatinized starch contained in saidmalt is converted into soluble carbohydrates and the yield of let of said heater tM-is connected with a tank 25p r'o vided with a mixer. A" pipe 26 leads from the bottom.

of the tank 26 to a plate and frame filter press27 from which filtrate may be passedto afilt'rate tank 29 through a pipe 28 The filtrate tank 29 is connected withanevapo; ra-tor 30 having 'a vapouroutlet 31'anid a concentrate As willbe seen rrqm'namhe heatexchanger 7 comprises three tubes33,"34 and '3 5 arranged one within the treated is formed between the tubes 33' and 34. Steam issupplied to the interior of the innermost tube 33am! to a heating jacket formed betweenthe tubes34 and 35. The steam is supplied at 37 in FIG. 1, and waste steam istaken off at 38. g The 'slurry from the vessel '1, which slurry is adjusted to a pH-value of about 6.5, is pumped by means of the diaphragm pump 3 through the heat exchanger 7, a'nd in a continuous *rythmically pulsating flow movement. v 1 During the passageof the medium through the heat exchanger 7', it is gradually heated to the selected liquefiying temperature, which as above explained is preferlique fying process has 'proceede'd'to a point where the t v medium is no lon er elatinizable b cooliir' fying enzymes to a temperature of between C. and g g y g soluble carbohydrates in the wort produced is consequently increased. Furthermore, the

Themedium thus treated is collected in the cyclone collector 10 and is subsequently pumped through the con- 'tinuous reactor vessel 13 whichare maintainedata temperature of about 86 C. 'The reactor vessels 13 are constructed in such a'manner that no back mixing takes place. "The number of reactor vessels is not critical, thus one or several reactorvessels mayrbe uscd..-The total residence time of the medium passing through'the reactor vessels is between 2 and 5 hours, depending on the amount of liquefying enzyme added.

When the medium leaves the reactor vessels 13 the Dextrose Equivalent value is for example about 15%.

In the cooler 14 the liquefied medium is cooled to a temperature of about 55 C. and subsequently the pH- value is adjusted 'to about 5.5 by introducing acid'such as hydrochloric'acid from the reservoir 19. The acidified medium isthen passed to one of the tanks 16.

Malt and proteinase are introduced into the tanks through the appropriate pipe 21 and the liquefied medium which is maintained at a temperature of about 55 C. is now subjected to the influence of the saccharifying enzymes and the proteinase.

The malt which is introduced into the tank 16 contains some non-gelatinized starchand in order to convert said. starch into soluble carbohydrates the medium is heated to a temperature of about 75 C. in the heater 24, and then passed to the tank 25 in which it is maintained at a temperature of 75 C. for a time sufficient to convert the starch introduced in the form of malt to soluble carbohydrates.

The medium is then pumped through the filter press 27 in which the insoluble materials are separated in the form of a filter cake. The filtrate passes through the pipe .28 tothe filtrate tank 29 and from this tank to the evaporator 30 in which it is concentrated to a total solids content of about 80%.

Referring to FIG. 2, the width of the passage 36; i.e. the distance between the walls of the tubes 33, 34 and the pressure and velocityot the medium are so selected that the medium, while flowing through the passage 36, will be subjected to considerable inner shearing forces producing a substantial thixotropie reduction of viscosity. The viscosity of the medium entering the tubular reactor .8 is reduced as a result of the enzymatic liquefaction conditions in the passage 36 and in the reactor 8. The passage 36 is, for example, about 9 mm. wide. The length of the passage 36 is, for example, between 15 and 30 metres and the length of the tubular reactor 8 is, for example, between 180 and 240 metres.

The pressure of the medium in the passage 36 is, for example, between 15 and 35 atm. The total residence time of the medium in the heat exchanger 7 and the tubular reactor 8 is preferably between 5 and 20 minutes, more preferably about minutes. Thus the velocity in the passage 36 is between 6 metres per minute and 0.75 metre per minute.

The residence time for the medium in the tank 16 depends on the quantity ofmalt used and may vary for example, between 2 and 16 hours; for example, if 2% malt is used'the residence time may be between 7 and 16 hours and if 10% malt is used the residence time may be 5 hours or less.

The medium from the reactor 20 is readily filterable and this obviates the use of complicated centrifuging equipment, and filter aid substances.

It appears that when barley is used a wort is produced which has substantially the same nitrogen content and carbohydrate spectrum aswort produced conventionally for beer brewing and is relatively light in colour. The wort maybe used directly without being made into a syrup'as a 'full replacement for a conventionally produced wort thus economising and simplifying plant or alternatively the syrup may be used to increase the throughput of a conventional process at peak times; in this case the syrup is diluted and added to conventionally produced wort.

Also it appears that the quality of the barley is not critical.

EXAMPLE I 48 kg. barley flour (43 kg. dry substance) were mixed with 120 kg. of water. The pH-value was adjusted to 6.5 with Na CO and 66 grams CaCl 2H O (calcium ions were found to enhance the stability of the a-amylase at high temperature) were added followed by 430 grams of commercial a-amylase preparation (NERVANASE 10.3 X marketed by ABM Industrial Products Limited of England).

The resulting slurry was pumped through the heat exchanger 7, the reactor 8 and the vessels 13 of the apparatus described with reference to the drawings at a rate of 128 litres per hour under conditions described with reference to the drawings. The total liquefaction time was 4 hours 43 minutes at 86 C. 1

The temperature of the product was lowered to 55 C. in the cooler 14 and the pH adjusted to 5.5 by means of HCI. Then 800 grams malt and 400 grams commercial proteinase (38.7 XS marketed by said ABM Industrial Products Limited) were added. After 16 hours the product was ready for filtration in the filter press 27.

The filtrate had a clear amber colour and a pleasant flavour. It was concentrated to about by weight total solids in the evaporator 30. The resulting wort concentrate is stable for long periods of time and can be diluted to any desired concentration before fermentation. The composition of the wort is given in Table Ifollowing these examples. The wort composition is in good agreement with the composition of wort prepared. by the traditional method where malt is the starting material, of. Table II.

EXAMPLE II 48 kg. barley flour (43 kg. dry substance) were mixed with kg. water. The pH-value was adjusted to 6.5 by means of Na C0 and 79 grams calcium acetate monohydrate were added followed by 215 grams commercial a-amylase preparation (NERVANASE 10.3 X).

The resulting slurry was pumped through the heat exchanger 7, the reactor 8, and the vessels 13 at a rate of 128 litres per hour. The total liquefaction time was 3 hours 2 minutes at 86 C.

The temperature of the product was lowered to 55 .C. in the cooler 14 and the pH-value adjusted to 5.5 by means of HCI.

4.8 kg. of malt and 215 grams of proteinase (38.7 XS) were added. After 5 hours the product was ready for filtration.

The resulting wort had the composition shown in Table I.

The filtration and concentration of the wortwere performed as described in Example I.

EXAMPLE III 78 kg. maize four (68 kg. dry substance) were mixed with kg. of water. The pH-value was adjusted to 6.5 by means of Na CO and 398 grams of CaCl 6H O were added followed by 680 grams of a commercial a-amplase preparation (NERVANASE 10.3 X).

The resulting slurry was pumped through the heat exchanger'7, the reactor 8 and the vessels 13 at a rate of 120 litres per hour. The total liquefaction time was 5 hours at 85 C. p

The temperature was then lowered to 55 C. in the cooler 14 and the pH-value adjusted to 5.5 by means of HCI.

t Then, 1300 grams of malt and 680 grams of proteinase (38.7 XS) were added. After 15 hours the product was ready for filtration.

The wort composition is given in the Table I.

The filtration and concentration of the wort were performed as described in Example I.

Wort produced according to the examples has been used for the preparation of beer. [In all cases, a panel of experts considered the beer very satisfactory with respect to flavour, appearance and composition. In fact the beer prepared from wort produced as described 8. A method according to claim 1 wherein said flow-is above is virtually indistinguishable from conventionally apulsating flow. produced beer; a i 9. A method according to claim .1, wherein said pas- Example 7 A I,

. I I 11 new material Barley flour Barley flour I s Maize flour I v Liqultylng enzyme concentration 19% bysyeitht of barley (dry 0.5b% i2y weight of barley (dry 1% by weight of malze-(drybasls) Proteinase concentration 1% (dry basis) 0.5% (dry basis) 1% (dry g v Malt concentration. (dry asis) -e (dry basis) 2% (dry basis). a Liquii'aetion, e 4 hours 43 minutes hours 0.2 minutes. 5 hours 00 minutes. Beoeharifleation, time 16 hours 5 h011rs.. hours. 1-.4 Delxtroee equivalent plus (DE) after liquefac- 18-6 percent 12-6 percent 29,0 percent. 1 lton. DE enersaceharifleation 43.9 percent 46.6 percent 45.7 percent. Com ition oiwort: I i n otein (NX6.25) 4.3% ry basis) 3.8% (dry basis) 1.4 (dry basis).

Amino nitrogen (alpha) y basis) y i an; 2.9% (dry basis) 1.9% (dry basis)-. a

Itthe wortlsto be used for the preparation of beer minor amounts of soluble protein can be added. v i; p The saccharide spectrum of the wort prepared as de- 20 sage'is annular,the slurry passingthrou'gh scribed in Examples I, II and III appears from the folwhile being heated to said temperature between 160" C. lowingTableII. n 100 C r TABLE II 10. A method according to claini'fl whreinsaid wort is fermented to produce beerl' Q 1 11. A method of producing wort from an unmalted Example Examp lg E3 cereal grain comprisingthe steps of a [Percent by weight] sun I arm distribution providing a slurry of the grain in water having a handi 5:; 2:8 1%; ness between 200 and 300 equivalent parts by weight 23.5 20.5 s.1 of CaCO per million parts by weight of water? 8 Welland m9 liquefying starch by treating theslurry with a commer 1m only, I cial starch liquefying enzyme at a temperature 1 W6 claim: I tween 60 C. and 100 C., j a 1. A method of producing wort from an unmalted sublectmg the 1 'Y'1 W a fldl banal grain comprising the steps of 6 meters per minute and 0,75 meter per minute uh Providing a slurry of the grain in water, 4a e rs 15 as t s e a "9"? liquefying starch by treating the slurry with a comy 8 tantlal'thixotropic {eductlon 9 KY'! mefical starch liquefying enzyme at a temperature produced by shearing forces in the slurry to facilitate between 600 and 1000 C the action at the starch liquety ng-enz'yme' prior to subjecting the slurry to flow through a passage whereby 40 I any substanilalfeductQn of S9 FYI= 8i m a substantial thixotropic reduction of viscosity is .prothe ePzymatlc hquefacnon; v duced by shearing forces in the slurry to facilitate E starch 9 sugar y treatment wlth 3 the action of the starch liquefying enzyme prior to chanfylong l? f a l fd tWccn'ZS C. any substantial reduction of viscosity resulting from 6 the enzymatic liquefaction 1 a H converting protein to soluble mtrogen-contaimngcomcooling the product thus obtained to a temperature 'be I Pounds by treatment wlth 3.. .enzyme a a tween 250 and C and J temperature between 25 C. and 60 C. i I adding a sac'chafifyin'g enzyme and a mi b 12. A method according to claim 11, wherein the slurry V enzyme, at id temperature to convert starch into after being subjected to said flow is treated-simultaneously sugar and protein into soluble nitrogen containing wlth the pl'oteolytlc enzyme imdrthe g g enzyme compounds.- atatemperature between 25 C. and 60 C. I

2. A method according to claim 1, wherein after vis- A method according to claim 1 whclfiin Said 110W cosity has been reduced as a result of the enzymatic liqueis a pulsating flow.

' a faction, the slurry is conducted through conduit means 14. A method according to claim 11, wherein saidflow by concentrating wort producted by a method according US. Cl: -X.R. o claim 1.

f ta length sufficient to increase liquefaction to a point is a'pulsatiug flow thr9ugh a passage s e q where the slurry is no longer gelatinisable by cooling. section and the slurry 1s sub ected to the flow while '3. A method according to claim 1 wh i th h d. heated to said temperature between C. and 100. 'C. ness of the water of the slurry is between 200 and 300 f Citd j I V I equivalent parts by weight of CaCO per million partsby Re ennces r I weight of water. 60 UNITED STATES PATENTS 4. 'A method acclording to claim 1 wherein the cereal 2 790 718 4/1957 Nugey 9 x grain comprises bar ey. 7 p r 5. Amethod according to claim 1 wherein said flow I gL through a passageiis at a pressure between 15 and 35 at- 1 3/1963 Dennis et aL 9 mospheres, and a flow velocity of the slurry between 6 3308037 3/19'67 G at i R metres per minute and 0.75 metre per minute. 1

E t l. 19' 6. A method according to claim 1 wherein the cooled 9 2/1968 wmg e a I FOREIGN PATENTS product treated with proteolytic and saccharifying enzy- 7 we me is eq y. heated to a p r ur we 501,672 4/1954 Canada f' 99 -51 C. and C. to convert non-gelatinised starch into 70 p v v soluble carbohydrate JOSEPH M.GOLIAN,PrimaryExaminer 7. A process of producing a'concentrated wort syrup is Patent No. 3,679,431 Dated v JuLX 25,Il972 David Henry Clayton and John Karkalas It is certified that error appears in the above-identified patent and that said Letters Patent-are hereby corrected as shown below:

In Column 1, Line 5, after "Denmark", insert assignors to A, B.M. IndustrialProducts Limited, Woodley, Stockport, Cheshire, England, and Karl Kristian Kobs Kroyer, Aarhus Viby, Denmark Signed and sealed this 20th day of February 1973 (SEAL) Attost:

EDWARD M.FLETCHRR,JR. ROBERT GOTTSCHALK Attesting Officer Commissioner of Patents FORM PO--1050 (10-69) USCOMM DC 603764509 f u.sv GOVERNMENT PRINTING OFFICE: was 0-366334 

